EP0138990A1 - Preparation de polymeres aromatiques - Google Patents

Preparation de polymeres aromatiques

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Publication number
EP0138990A1
EP0138990A1 EP84901676A EP84901676A EP0138990A1 EP 0138990 A1 EP0138990 A1 EP 0138990A1 EP 84901676 A EP84901676 A EP 84901676A EP 84901676 A EP84901676 A EP 84901676A EP 0138990 A1 EP0138990 A1 EP 0138990A1
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European Patent Office
Prior art keywords
accordance
amount
chloride
weight
monomer system
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German (de)
English (en)
Inventor
Viktors Jansons
Heinrich Carl Gors
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Raychem Corp
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Raychem Corp
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G67/00—Macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing oxygen or oxygen and carbon, not provided for in groups C08G2/00 - C08G65/00
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G61/00—Macromolecular compounds obtained by reactions forming a carbon-to-carbon link in the main chain of the macromolecule
    • C08G61/12—Macromolecular compounds containing atoms other than carbon in the main chain of the macromolecule
    • C08G61/127—Macromolecular compounds containing atoms other than carbon in the main chain of the macromolecule derived from carbon dioxide, carbonyl halide, carboxylic acids or their derivatives

Definitions

  • This invention relates to a method of preparing poly(arylene ketones) and in particular to an electrophilic polymerization process for preparing such polymers.
  • the aration of poly(arylene ether ketones) by two different aches has been described in the literature. The first ap oach is an electrophilic synthesis in which an aryl ketone linkage is formed. The second is a nucleophilic synthesis in which an aryl ether linkage is formed.
  • This invention is directed to an improved electrophilic synthesis f ⁇ r preparing poly(arylene ketones), in particular paralinked poly(aryl ether ketones).
  • the polymer ⁇ step involves the formation of an aryl ketone group a carboxylic acid or acid derivative group and an aromatic compound containing an aromatic carbon bearing an activated hydrogen atom, i.e. a hydrogen atom displaceable under the electrophilic reaction conditions.
  • the monomer system employed in the polymerization can be, for example, (a) a single aromatic compound containing both a carboxylic acid or acid derivative group as well as an activated hydrogen atom on an aromatic carbon for example, p-phenoxybenzoyl chloride; or (b) a two-component system of a dicarboxylic acid or acid derivative and an aromatic compound containing two activated hydrogen atoms, for example, 1 ,4-diphenoxybenzene and terephthaloyl chloride.
  • Electrophilic polymerization of this type is often referred to as Friedel-Crafts polymerization.
  • a reaction medium comprising the reactant(s), a catalyst, such as anhydrous aluminum trichloride, and solvent such as methylene chloride, carbon disulfide, nitromethane, nitrobenzene, or orthodichlorobenzene.
  • a catalyst such as anhydrous aluminum trichloride
  • solvent such as methylene chloride, carbon disulfide, nitromethane, nitrobenzene, or orthodichlorobenzene.
  • the aluminum trichloride catalyst is generally employed in an amount greater than one equivalent far each equivalent of carbonyl groups in the reaction medium.
  • Other inorganic halides such as ferric chloride may be employed as the catalyst.
  • Such Friedel-Crafts polymerizations generally have produced an intractable reaction product difficult to remove from the reaction vessel and purify. Further, such processes have tended to produce polymer of undesirably low molecular weight and/or of poor thermal stability.
  • the all para-linked poly(arylene ether ketones) have been particularly difficult to prepare under such Friedel-Crafts conditions.
  • One factor that appears to contribute to the unsatisfactory results reported in the literature is that the para-linked polymers are more highly crystalline than the ortho, meta or mixed isomeric members of this polymer family and are therefore generally more insoluble in the reaction media typically used in such Friedel-Crafts reactions. This tends to result in the premature precipitation of the polymer in low molecular weight form.
  • the process of this invention provides a high reaction rate which enables the reaction to be carried out at relatively low temperatures over a relatively short period of time. Further, the polymer is maintained in the reaction medium, for example in solution or in a reactive gel state, until high molecular weight polymer is obtained. Further, the polymer produced is essentially linear with little, if any, ortho substitution of the aromatic rings in the polymer backbone. Since the process of this invention maintains the polymer in solution or in a more tractable state, recovery and purification of the polymer is greatly facilitated.
  • Figure 1 is a graph illustrating the effect of the amount of Lewis acid present during the polymerization on the inherent viscosity of poly(carbonyl-p-phenylene-oxyp-phenylene). Summary of the Invention
  • the Friedel-Crafts polymerization of appropriate monomer systems is. controlled to suppress ide reactions including ortho substitution, alkylation and chain branching and/or to solubilize or swell the polymer, by conducting the reaction under select reaction conditions and proportions of reactants not taught or suggested by the prior art or by the addition of a controlling agent, such as a Lewis base, to the reaction medium or both.
  • a controlling agent such as a Lewis base
  • One aspect of this invention comprises a method of producing a poly(arylene ether ketone) which comprises polymerizing (I) phosgene or an aromatic diacid dihalide together with a polynuclear aromatic comonomer. containing two active hydrogen atoms or (II) a polynuclear aromatic comonomer containing both an acid halide group and an active hydrogen atom, in the presence of a Lewis acid, optionally a controlling agent and optionally a non-protic diluent, the various components being present in such proportions and the polymerization being conducted under such reaction conditions that a thermally stable, linear poly(arylene ether ketone) substantially free of pendant groups resulting from ortho substitution of para-linked aromatic rings in the polymer backbone is obtained.
  • Another aspect of this invention comprises a method of producing poly(arylene ether ketones) which comprises polymerizing a monomer system comprising: I) (i) phosgene or an aromatic diacid dihalide together with
  • each Ar is independently selected from substituted or unsubstituted phenylene, and substituted and unsubsti-tuted polynuclear aromatic moieties free of ketone carbonyl or ether oxygen groups;
  • the monomer system includes a, diacid dihalide and a comonomer as defined in I(ii)(a) , I(ii)(b) or I(ii)(d):
  • the Lewis acid is present in excess of the minimum specified in A) above by an amount of up to about 0.8 equivalents per equivalent of undeactiv ated aryloxy groups in the monomers, and, if the acid halide groups are situated on separate non-fused aromatic rings, by an additional amount of up to about 0.5 equivalents per equivalent of acid halid groups;
  • the concentration of monomers in the reaction mixture is at at least about 7 % by weight, based on the total weight of the reaction mixture; with the further proviso that when the monomer system includes a comonomer as defined in I(ii)(a) and the diacid dihalide is benzene dicarbonyl dichloride or diphenyl ether dicarbonyl dichloride, the polymer produced is at least partially crystalline;
  • the Lewis acid is present in excess of the minimum specified in (A) above by an amount of up to 0.8 about equivalent per equivalent of undeactivated aryloxy groups in the monomers ;
  • the monomer system is I(c) or II
  • the Lewis acid is present in an amount in excess of the minimum specified in A) above by at least about 0.6 +[0.25 X tanh (50(0.1-D)] equivalents per equivalent of acid halide groups where D is the molar ratio of monomer to diluent.
  • a poly(arylene ether ketone) is produced from an appropriate monomer system.
  • the polymers produced by the process of the invention have repeat units of the general formula
  • each Ar is independently selected from substituted and unsubstituted phenylene and substituted and unsubstituted polynuclear aromatic moieties.
  • polynuclear aromatic moieties is used to mean aromatic moieties containing at least two aromatic rings.
  • the rings can be fused, joined by a direct bond or by a linking group.
  • the acid halide monomers and certain diacid dihalides at least two of the aromatic rings are linked by an ether oxygen linkage.
  • Other linking groups which can join aromatic rings in the aromatic moieties include for example, carbonyl, sulfone, sulfide, amide, imide, azo, alkylene, perfluoroalkylene and the like.
  • the phenylene and polynuclear aromatic moieties can contain substitutents on the aromatic rings. These substituents should not inhibit or otherwise interfere with the polymerization reaction to any significant extent. Such acceptable substituents include, for example, phenyl, halogen, nitro, cyano, alkyl, 2-aralkenyl, alkynyl and the like.
  • These polymers are prepared in accordance with this invention by polymerizing an appropriate monomer system.
  • Such monomer systems comprise:
  • each Ar is independently selected from substituted or unsubstituted phenylene, and substituted and unsubstituted polynuclear aromatic moieties free of ketone carbonyl or ether oxygen groups.
  • Aromatic diacid dihalide employed is preferably a dichloride or dibromide.
  • Illustrative diacid dihalides which can be used include, for example
  • Illustrated polynuclear aromatic comonomers which can be used with such diacid halides are:
  • H-Ar-O-Ar-H which includes, for example:
  • Monomer systems II and III comprise an acid halide.
  • acid halide is used herein to refer to a monoacid monohalide.
  • the acid halide is of the formula
  • the acid halide is of the formula
  • the monomer system is polymerized in the presence of a reaction medium comprising:
  • Lewis acid is used herein to refer to a substance which can accept an unshared electron pair from another molecule.
  • Lewis acids which can. be used in the practice of this invention include, for example, aluminum trichloride, aluminum tribromide, antimony pentachloride, antimony pentafluoride, indium trichloride, gallium trichloride, boron trichloride, boron trifluoride, zinc chloride, ferric chloride, stannic chloride, titanium tetrachloride, and molybdenum pentachloride.
  • substantially anhydrous aluminum trichloride as the Lewis acid is preferred.
  • the amount of Lewis acid used in the practice of this invention varies depending on the particular monomers and reaction medium selected. In all instances at least about one equivalent of Lewis acid per equivalent of carbonyl groups present in the monomer system is used plus an amount effective to act as a catalyst for the polymerization (also referred to herein as a catalytic amount). Generally a catalytic amount added is from about 0.05 to about 0.3 equivalents of Lewis acid per equivalent of acid halide in the reaction mixture. Additional amounts of Lewis acid are also required depending on the nature of the m.onomers and the reaction conditions in a manner as set forth below.
  • the Friedel-Crafts polymerization reaction is controlled by the addition of a controlling agent or by varying the reaction conditions, including varying the amount of Lewis acid to achieve the desired melt-pr ⁇ cessable, high molecular weight, substantially linear poly(arylene ether ketones).
  • the polymerization reaction is controlled by the addition of a controlling agent which, inter alia, suppresses undesirable side reactions, particularly ortho substitution of ac t iv a te d aryloxy groups. Suppression of side reactions results in a polymer that is thermally stable, that is it does not degrade or cross-link when subjected to elevated temperatures, e.g. temperatures above the melting point of the polymer, for a period of time. For a polymer of this type to be suitable for melt processing, it must be able to withstand the processing temperatures for the required processing time.
  • the polymer can withstand temperatures up to about 30°C above the melting or softening point of the polymer for periods of at least 30 minutes, preferably at least.60 minutes and most preferably at least 90 minutes, without undesired gel formation or substantial change in inherent viscosity.
  • Lewis bases are Lewis bases.
  • the term "Lewis base” is used herein to refer to a substance capable of donating an unshared electron pair to a Lewis acid.
  • the Lewis base forms a complex with the Lewis acid used in the reaction medium. It has been found that Lewis bases whrch form a 1:1 complex having a heat of association at least about that of diphenyl ether with the Lewis acid are preferred.
  • the Lewis base used should form a 1:1 complex having a heat of association of at least about 15 kcal/mole, preferably at least about 20 kcal/mole and most preferably at least about 30 kcal/mole.
  • Typical Lewis bases which can be employed include, for example, amides, amines, esters, ethers, ketones, nitriles, nitro compounds, phosphines, phosphine oxides, phosphoramides, sulfides, sulfones, sulfonamides, sulfoxides and halide salts.
  • Examples of specific organic Lewis bases that can be used in the practice of this invention are acetone, benzophenone, cyclohexanone, methyl acetate, ethylene carbonate, N-methylformamide, acetamide, N,N-dimethylacetamide, N-methylpyrrolidone, urea, tetramethylurea, N-acetylmorpholine, dimethyl sulfoxide, N, N-dimethylformamide, diphenyl sulfone, N, N-dimethylmethanesulfonamide, phosphoryl chloride, phenylphosphonyl chloride, pyridine-N-oxide, triphenylphosphine oxide, trioc tylphosphine oxide, nitropropane, nitrobenzene, benzonitrile, n-butyronitrile, methyl ether, tetrahydrofuran, dimethyl sulfide, trimethylamine, N, N, N' , N'
  • suitable Lewis bases include inorganic salts which can form complexes with Lewis acids, for example, chlorides, such as trimethylammonium chloride, tetramethylammonium chloride, sodium chloride or lithium chloride, perchlorates, trifluoromethanesul fonates and the like.
  • Preferred Lewis bases for the reaction medium of this invention are N-methyl formamide, N,N-dimethylformamide, N, N-dimethylacetamide, 1 -methyl-2-pyrrolidone, tetramethylene sulfone (also known as sulfolane), n-butyronitrile, dimethyl sulfide, imidazole, acetone, benzophenone, trimethylamine, trimethylamine hydrochloride, tetramethylammonium chloride, pyridine-N-oxide, 1-ethylpyridinium chloride, lithium chloride, lithium bromide, sodium chloride, sodium bromide, potassium chloride, potassium bromide and mixtures thereof.
  • the amount of Lewis base present should be from 0 to about 4 equivalents per equivalent of acid halide groups present in the monomer system. Amounts greater than 4 equivalents could be employed, if desired. However, no additional controlling effect is usually achieved by adding larger amounts. Thus, it is preferred to use no more than about 4 equivalents and generally about 2 equivalents.
  • a Lewis base is added to control the reaction at least about .01, preferably at least about 0.05 and most preferably at least about 0.5 equivalents of Lewis base per equivalent of acid halide groups present should be used.
  • the particular amount of Lewis base added depends to a certain extent on the nature of the monomers present.
  • the temperature at which the reaction is conducted can be from about -50°C to about +150°C.
  • the temperature can be raised if desired, for example, to increase the rate of reaction. It is generally preferred to carry out the reaction at temperatures in the range of between about -30oC and +25°C (room temperature). While it is not understood exactly how the Lewis base acts to control the reaction, it is believed that one or more of the following factors may be involved.
  • the Lewis acid/Lewis base complex appears to act as a solvent for the polymer-Lewis acid complex formed during the reaction, thereby maintaining the polymer in solution or in a reactive gel state.
  • the reaction mixture is more tractable, making work up of the polymer easier and ensuring effective removal of catalyst residues during purification.
  • the solubilization property of the Lewis acid/Lewis base complex is particularly significant in the preparation of para-linked poly(arylene ether ketones).
  • these polymers are more highly crystalline than other members of this polymer family and their complexes with the Lewis acid tend to precipitate from the reaction medium in low molecular weight form and/or in a particularly intractable mass difficult to recover and purify.
  • a diluent such as methylene chloride or dichloroethaoe
  • the Lewis acid/Lewis base complex reduces the tendency of the diluent to act as an alkylating agent by competing with the diluent for available Lewis acid and thereby suppressing alkylation of the polymer.
  • Alkylation of the polymer in the para position caps the reaction while alkylation in the ortho position introduces undesired reactive sites in the polymer chain which can lead to branching or cross-linking.
  • the aromatic rings which are particularly susceptible to ortho substitution are active aryl ⁇ xy groups. Such groups are referred to herein as undeactivated aryloxy groups.
  • undeactivated aryloxy group is meant an aryloxy group which is in a molecule in which there are no deactivating groups or is located at least two aromatic moieties (i.e. Ar as defined above) away from a deactivating group such as a carbonyl.
  • a deactivated aryloxy group is an aryloxy group separated from a deactivating group, usually carbonyl, by an aromatic group containing one aromatic ring, fused aromatic rings or aromatic rings linked by direct bonds.
  • a non-protic diluent can also be employed, if desired.
  • the diluent should dissolve the Lewis acid/ Lewis base complex and the resulting polymer/Lewis acid complex. It should also be relatively inert toward FriedelCrafts reactions.
  • the diluent is preferably somewhat polar as measured by its dielectric constant and solubility parameter.
  • the dielectric constant of the diluent is at least about 2.5 at 24°C, and preferably in the range of from about 4.0 to about 25 at 24°C.
  • Hildebrand solubility parameter of the diluent is preferably at least about 7.2 [cal/cm 3 ] 1/2 and is preferably in the range of from about 9.2 to about 15 [cal/cm 3 ] 1/2 .
  • Preferred diluents include, for example, methylene chloride, carbon disulfide, o-dichlorobenzene, 1,2,4-trichlorobenzene, o-difluorobenzene, 1,2-dichloroethane, 1,1,2,2-tetrachloroethane and mixtures thereof.
  • the diluent is used in an amount from 0 to about 93% by weight, based on the weight of the total reaction mixture.
  • the reactions can be run neat, that is without the presence of a diluent. This is true for the process of this invention whether or not a Lewis base is used.
  • the monomer to diluent molar ratio can contribute to control of the polymerization reaction to yield the desired product.
  • the diluent is used in an amount of at least about 10%, preferably at least about 20% by weight based on the weight of the reaction mixtures.
  • the polymerization reaction can also be controlled by us'e of the appropriate reaction conditions without the addition of a Lewis base.
  • the term substantial absence of Lewis base is used herein to refer to reaction mixtures to which no Lewis base is added as a controlling agent. Minor amounts of Lewis base may be generated in situ during the polymerization reaction, but such amounts are inadequate to control the reaction.
  • the reaction conditions required depend on the reactivity of the monomers used. Two general classes of monomers need to be considered - those containing undeactivated aryloxy groups as defined above and those which do not. If any monomer in the monomer system contains an undeactivated aryloxy group, the amount of Lewis acid used generally should not exceed a certain amount.
  • Monomer systems which can be used in the practice of this invention have been defined above with consideration of the reactivity of the aryloxy groups present.
  • the conditions under which the polymerization will be controlled to produce the desired product can then be set forth, with further requirements provided where the relative activity of the acid halide groups make this necessary.
  • the monomer systems are:
  • each Ar is independently selected from substituted or unsubstituted phenylene, and substituted and unsubstituted polynuclear aromatic moieties free of ketone carbonyl and ether oxygen groups.
  • Monomer systems that contain undeactivated aryloxy groups are I wherein the comonomer is as defined in I(ii)(a), I(ii)(b), I(ii)(d) and III.
  • the amount of Lewis acid present in addition to the above noted one equivalent per equivalent of carbonyl groups present plus an amount effective to act as a catalyst for the polymerization should be less than 0.8 equivalents per equivalent of undeactivated aryloxy groups. Preferably even less than that should be used, for example less than about 0.6 equivalents and most preferably less than about 0.4 equivalents per equivalent of undeactivated aryloxy groups present.
  • the concentration of monomers in the reaction mixture be at least about 7%, preferably at least about 10%, and most preferably at least about 15%, by weight based on the total weight of the reaction mixture.
  • the second general class of monomers are monomer systems which contain no undeactivated aryloxy groups. Monomers of this type are set forth in monomer system I wherein the comonomer is as defined in I(ii)(c) and II. With this class of polymers it is preferred to use a large excess of Lewis acid, the excess depending on the particular monomer to diluent molar ratio (D). Generally, it is preferred. to have a relatively high monomer to diluent ratio and a relatively large excess of Lewis acid.
  • the amount of excess Lewis acid (in addition to the above noted equivalent per equivalent of carbonyl groups plus a catalytic amount) is at least about 0.6 + (0.25 X tanh [50(0.1-D)]) equivalents per equivalent of acid halide groups.
  • the amount of excess Lewis acid is prefeably at least about 0.8 + (0.25 X tanh [50(0.1-D)]) and most preferably is at least about 1.0 + (0.25 X tanh [50(0.1-D)]) equivalents per equivalent of acid halide groups.
  • the amount of Lewis acid in excess of the standard amount is at least about 0.3 equivalents per equivalent of acid halide groups.
  • Lewis acid in a substantial excess of the minimum amounts specified.
  • at least about 0.5 equivalent and preferably at least about 1.0 equivalents of additional Lewis acid, per equivalent of acid halide groups are used.
  • poly(arylene ketones) of high molecular weight can be obtained.
  • high molecular weight polymer having an inherent viscosity greater than about 0.6.
  • the polymer prepared by the process of this invention has an inherent viscosity in the range of about 0.6 to about 2.0.
  • Polymers having an inherent viscosity below about 0.6 are generally not useful because they have poor mechanical properties, such as tensile strength and elongation. They also tend to be brittle while polymers having an inherent viscosity above about 2.0 are very difficult to melt process.
  • inherent viscosity refers to the mean inherent viscosity determined according to the method of Sorenson et al, "Preparative Methods of Polymer Chemistry” Interscience (1968), at page 44 [0.1g polymer dissolved in 100 ml of concentrated sulfuric acid at 25°C].
  • the molecular weight of the polymer, the degree of branching and amount of gelation can be controlled by the use of, for example, capping agents as described in U.S. Patent No. 4,247,682 to Dahl, the disclosure of which is incorporated herein by reference.
  • the molecular weight of the polymer can also be controlled by a polymerization reaction utilizing a two-monomer system as described above, by employing a slight excess of one of the monomers.
  • Capping agents when employed, are added to the polymerization reaction medium to cap the polymer on at least- one end of the polymer chain. This terminates continued growth of that chain and controls the resulting molecular weight of the polymer, as shown by the inherent viscosity of the polymer. Judicious use of the capping agents results in a polymer within a selected narrow molecular weight range, decreased gel formation during polymerization, and decreased branching of the polymer chains and increases melt stability. Both nucleophilic and electrophilic capping agents are used to cap the polymer at each end of the chain.
  • Preferred nucleophlic capping agents are 4-chlorobiphenyl, 4-phenoxybenzophenone, 4-(4-phenoxyphenoxy)benzophenone, biphenyl 4-benzenesulfonylphenyl phenyl ether, and the like.
  • Typical electrophilic capping agents are compounds of the formula
  • Ar is phenyl, 3-chlorophenyl, 4-chlorophenyl, 4-cyanophenyl, 4-methylphenyl or an aromatic group substituted with an electron withdrawing substituent and E is halogen or other leaving group.
  • Preferred electrophilic capping agents include benzoyl chloride, benzenesul fonyl chloride and the like.
  • the Lewis acid/Lewis base complex solubilizes or solvates the polymer so that it remains in the reaction medium in a form capable of sustaining continued polymerization so that the desired high molecular weight is obtained in a controlled and reproducible fashion.
  • Lewis acid is also present in the reaction medium as the catalyst for the Friedel-Crafts polymerization reaction.
  • the resulting polymer contains Lewis acid complexed to the carbonyl groups of the polymer.
  • the Lewis acid is complexed to substantially all. the carbonyl groups in the polymer.
  • the catalysit residue must be removed, i.e. the Lewis acid must be decomplexed from the polymer and removed.
  • a method for removing the catalyst residue is described in U.S. Patent No. 4,237,884 to Dahl, the disclosure of which is incorporated herein by reference.
  • Decomplexation can be accomplished by treating the polymerization reaction mixture with a decomplexing base after completion of polymerization.
  • the base can be added to the reaction medium or the reaction medium can be added to the base.
  • the decomplexing base must be at least as basic towards the Lewis acid as the basic groups on the polymer chain. Such decomplex ation should be effected before isolation of the polymer from the reaction mixture.
  • the amount of decomplexing base used should be in excess of the total amount of bound (complexed) and unbound Lewis acid present in the reaction mixture and is preferably twice the total amount of Lewis acid.
  • Typical decomplexing bases which can be used include water, dilute aqueous hydrochloric acid, methanol, ethanol, acetone, N, N-dimethylformamide, N, N-dimethylacetamide, pyridine, dimethyl ether, diethyl ether, tetrahydrofuran, trimethylamine, trimethylamine hydrochloride, dimethyl sulfide, tetramethylenesulfone, benzophenone, tetramethylammonium chloride, isopropanol and the like.
  • the decomplexed polymer can then be removed by conventional techniques such as adding a nonsolvent for the polymer which is a solvent for or miscible with the Lewis acid/Lewis base complex and the Lewis acid; spraying the reaction medium into a non-solvent for the polymer; separating the polymer by filtration: or evaporating the volatiles from the reaction medium and then washing with an appropriate solvent to remove any remaining base/catalyst complex and diluent from the polymer.
  • a nonsolvent for the polymer which is a solvent for or miscible with the Lewis acid/Lewis base complex and the Lewis acid
  • spraying the reaction medium into a non-solvent for the polymer separating the polymer by filtration: or evaporating the volatiles from the reaction medium and then washing with an appropriate solvent to remove any remaining base/catalyst complex and diluent from the polymer.
  • reaction mixture In recovery of the polymer from the reaction mixture, the reaction mixture can be liquified, if desired by the method described in application Serial No. (atty's docket no. ) of R. Reamey, the disclosure of which is incorporated herein by reference.
  • a 500 ml 3 neck round bottom flask equipped with a stirrer, thermometer, and nitrogen inlet was charged with 1 ,4-diphenoxybenzene (13.2198 g, 0.0504 mole), terephthaloyl chloride (10.1515 g, 0.0500 mole), benzoyl chloride (0.1.124 g, 0.0008 mole), sulfolane (27.04 g, 0.225 mole), and anhydrous methylene chloride (150 milliliters, ml).
  • the atmosphere inside the flask was purged with and kept under nitrogen.
  • the flask and its contents were cooled to -40°C with a dry ice-acetone bath.
  • N, N-dimethylformamide (DMF,5.54 g, 75.8 mmole, freshly vacuum distilled from calcium hydride) in methylene chloride (15 ml) was added slowly (to control the vigorous exotherm). With continued cooling, a solution of 1, 4-diphenoxybenzene (6.6811 g, 25.5 mmole) , terephthaloyl chloride (5.1302 g, 25.3 mmole), and benzoyl chloride (0.571 g, 0.40 mmole) in methylene chloride (25 ml) was added. The transferring flask was rinsed with an additional volume of methylene chloride (10 ml) to ensure complete transfer.
  • DMF 1, 4-diphenoxybenzene
  • terephthaloyl chloride (5.1302 g, 25.3 mmole)
  • benzoyl chloride 0.571 g, 0.40 mmole
  • the stirred reaction mixture was allowed to warm up to room temperature over a 6.3 hour period, during which time it became a viscous orange-red suspension. It was next cooled down to 5-6oC with an ice bath and the reaction was quenched with DMF (50 ml). At this time, the polymerization mixture became a highly viscous white slurry. The polymer was isolated by filtration, transferred into a 1 qt. glass blender containing cold (0°C) DMF (100 ml), and blended at high speed until room temperature was reached. This process was repeated.
  • polymer was then digested twice in DMF (250 ml, 50°C, 24 hrs) , once in water (300 ml, room temperature, 24 hours), and once in hydrochloric acid (0.5 M, 500 ml, room temperature, 24 hours). After washing with more water and vacuum drying, polymer (8.9g, 90% yield) of inherent viscosity 1.2 (0.1% in sulfuric acid) was obtained. Its melt stability and processability were demonstrated by the fact that slabs pressed for 30 min at 400°C showed minimal change in inherent viscosity. Ex amp l e 3
  • Example 2 The procedure of Example 2 was repeated using terephthaloyl chloride (5.17 g, 25.2 mmole), 1 , 4-diphenoxybenzene (6.56 g. 25.0 mmole) and 4-(4-phenoxyphenoxy) benzophenone (0.1466 g, 0.4 mmole) .
  • the resultant, polymer had an inherent viscosity of 1.25. Polymsr pressed for 30 minutes at 400°C gave slabs of inherent viscosity 1.34 (average of 2 samples). Pressing at 410oC for 30 minutes gave slabs of inherent viscosity 1.71 (average of 3 samples), with a slight amount of gel.
  • Example 2 The procedure of Example 2. was repeated using purified aluminum chloride. The initial temperature employed was -15°C and the reaction mixture was allowed to warm up to 8°C. The aluminum chloride was purified prior to introduction into the reaction medium by vacuum distillation from a mixture of 1500 g aluminum chloride, 100 g sodium chloride and 5 g aluminum powder followed by vacuum sublimation.
  • the polymer thus obtained had an inherent viscosity of 1.17 (average of 2 samples). Slabs pressed at 400 or 410°C for 30 minutes had inherent viscosities of 1.15 (average of 4 samples) and 1.18 (average of 4 samples), respectively. No gel was observed in any of the slabs.
  • the polymer was recovered by transferring the polymerization mixture into methanol (about 100 ml), breaking it up in a blender at high speed, filtering, and washing generously with methanol. After digesting overnight in more methanol (about 100 ml) at room temperature, the polymer was washed with water and vacuum dried (120-160°C). The product was a white polymer of inherent viscosity 1.69. When compression molded at 400oC for 3 min, it formed a transparent yellow, tough, flexible slab.
  • Example 5 was repeated, except that o-dichlorobenzene was used in place of the methylene chloride.
  • the resultant polymer was light yellow and had an inherent viscosity of 1.12. It could be pressed at 400°C into a tough, flexible, pale yellow slab.
  • Example 5 was repeated, except that DMF was substituted for n-butyronitrile and o-difluorobenzene for methylene chloride.
  • the resultant polymer was light yellow and had an inherent viscosity of 1.18. It could be pressed into a tough, flexible, pale yellow slab.
  • Example 5 was repeated, except that DMF was substituted for n-butyronitrile and 1 , 2, 4-trichlorobenzene for methylene chloride.
  • the resultant polymer was white and had an inherent viscosity of 1.50. It could be pressed into a flexible, light colored slab.
  • Diphenyl ether (1.7025 g, 0.010 mole) was pclymerized with terephthaloyl chloride (1.6242 g, 0.008 mole) and isophthaloyl chloride (0.04058 g, 0.002 mole) in the presence of methylene chloride (14 ml), trimethylamine hydrochloride (2.19 g, 0.023 mole), and aluminum chloride (6.0 g, 0.045 mole) by the procedure described in example 5.
  • the resultant polymer had an inherent viscosity of 0.74. It could be pressed into a slab that was light colored and flexible.
  • N-succinimido derivative of p-phenoxybenzoic acid (1.200 g, 0.004 mole) was polymerized in methylene chloride (6 ml), trimethylamine hydrochloride (1.50 g, 0.016 mole), and aluminum chloride (4.40 g, 0.033 mole) according to the procedure in example 5.
  • the resulting polymer had an inherent viscosity of 0.95 and could be pressed into a flexible tan slab.
  • the polymer was recovered by decomplexation of the mixture with water in a Waring blender, washing with a water/methanol solution, soaking the product in water overnight, then washing with methanol and drying.
  • the product was a colorless polymer having an inherent viscosity of 1.58. When compression molded at 400°C for 2 minutes, it formed e pale yellow, tough, flexible slab. Ex am p le 1 3
  • a 500 ml 3-neck round bottom flask equipped with a stirrer, thermometer and nitrogen inlet was charged with N, N-dirnethylformamide (16.45g, 0.2250 mole) and anhydrous methylene chloride (150 ml).
  • the atmosphere inside the flask was purged with nitrogen.
  • the flask was cooled to -30°C with a dry ice-acetone bath.
  • Compression molding at 400°C yielded a light colored, tough, flexible slab.
  • the slab became brittle on annealing.
  • Example 15 The procedure of Example 15 was repeated using 4,4'-diphenoxybenzophenone (2.162 g, 0.0059 mole), phosgene (1.43 g, 0.0144 mole), lithium chloride (1.00 g, 0.0236 mole) and aluminum trichloride (6.24 g, 0.0468 mole) in 1 , 2-dichloroethane (8 ml).
  • the resulting product (2.2 g, 94% yield) was an off-white polymer having a relatively high gel content which formed a yellow flexible slab when pressed at 400°C.
  • Ex amp le 1 6 Ex amp le 1 6
  • N,N-Dimethylformamide (DMF, 1.45 g, 0.020 mole) was added dropwise with cooling and stirring to anhydrous aluminum chloride (5.70 g, 0.043 mole). An exotherm ensued, leading to a hot, fluid melt with a few suspended aluminum chloride particles. The fluid was kept at 100-110°C for 5-10 minutes under nitrogen. Upon cooling, a light colored liquid was obtained, apparently containing some still undissolved aluminum chloride.
  • p-Phenoxybenzoyl chloride (3.00 g, 0.013 mole) was added with stirring. The entire mixture was heated according to the schedule in the accompanying table, cooled, and worked up by precipitating into methanol, washing with water and methanol, and drying.
  • Procedure B The reaction was carried out as above, but with the following amounts of chemicals: DMF (1.46 g, 0.02 mole), anhydrous aluminum chloride (5.32 g, 0.040 mole), and p-phenoxybenzoyl chloride (1.60 g, 0.007 mole). The polymerization mixture was not heated, but was instead maintained at room temperature for the times indicated.
  • a stock solution was prepared from p-phenoxybenzophenone (0.6165 g, 0.00225 mole), benzoyl chloride (0.3032 g, 0.00215 moles), dichloroethane (63.6 g) , and p-phenoxybenzoyl chloride (116.2 g, 0.400 mole) and stored at room temperature in a flask stoppered with an-air/no-air septum. This stock solution was sufficient for about twenty polymerizations of the scale below. Polymer pr e par ed from this stock solution is double-capped at 0.6 mole % (calculated from the ratio of p-phenoxybenzophenone, the limiting capping agent, to p-phenoxybenzoyl chloride).
  • a reactor consisting of 200 mL resin kettle and a top with four openings to which were attached a mechanical stirrer with a PTFE paddle, a 50 mL addition funnel, a glass-clad thermocouple probe and an inert gas supply tube . was assembled. (Glass equipment was dried at 100°C until just prior to use.) All ground glass joints were sealed with PTFE seals, except for the stirrer shaft which was sealed with vacuum grease. The assembled reactor was dried with a hot air gun or Bunsen burner while being flushed with nitrogen or argon. The inert gas atmosphere was maintained throughout the operations except for momentary interruptions for the addition of reagents.
  • the reactor was charged with, in order, anhydrous aluminum chloride (10.0 g, 0.075 mole, Witco #0099), lithium chloride (1.59 g, 0.0375 mole, ACS Reagent Grade), and 1, 2-dichloroethane (10.0 g) .
  • the white slurry was cooled to between -15 and -25°C with a dry ice/acetone bath.
  • Monomer stock solution (9.04 g) was added dropwise over a 7 minute period with continued stirring and cooling. After the completion of this addition, the reaction mixture's temperature was maintained at -15°C for one hour and then raised to 0°C and maintained there for 23 hours. Approximately 2-3 hours after addition of the monomers, a notable increase in viscosity occurred. At this point stirring became extremely difficult and was usually discontinued.
  • the polymer could be isolated by one of two workup procedures:
  • This example demonstrates the suppression of undesirable side reactions by polymerization in the presence of a Lewis base (in this case, lithium chloride).
  • a Lewis base in this case, lithium chloride.
  • Two polymerizations were performed, employing the procedure of Example 17, workup B, with the following exceptions: (1) the capping level was 0.45 mole%, (2) the time-temperature profile was 1 hr/0°C followed by room temperature reaction, and (3) one of the reactions was run without lithium chloride Aliquots were taken out at the times indicated in the accompanying table and figure, worked up, and analyzed.
  • Example 17 The procedure of Example 17, wgrkup A, was followed, with these exceptions: (1) p-phenoxybenzophenone (0.45 mole %) was the only capping agent and (2) the amount of 1,2-dichloroethane was adjusted to achieve the indicated per cent loading.
  • per cent loading is defined as 100 times the ratio of the theoretical yield (in grams) of polymer to the sum (in grams) of monomer, capping agent, Lewis acid, Lewis base, and solvent in the reaction mixture.
  • p-Phenoxybenzoyl chloride was polymerized as described in Example 17, workup B, except that no lithium chloride was used and p-phenoxy-benzophenone (0.45 mole % ) was the only capping agent used.
  • the results are provided in the table below which illustrate the effect of the amount of aluminum chloride on the inherent viscosity of the polymer.
  • the polymer was a white powder with inherent viscosity 1.03. A slab pressed at 400°C for 5 minutes was transparent and flexible.
  • p-Phenoxybenzoyl chloride was polymerized as in Example 17, workup A, except that (1) p-phenoxybenzophenone (0.45 mole % ) was the only capping agent, (2) the "per cent loading” was adjusted to the levels given below by varying the amount of 1,2-dichloroethane used, and (3) no Lewis base was added.
  • "per cent loading” is defined as 100 times the ratio of the theoretical yield (in grams) of polymer to the sum (in grams) of monomer, capping agent, Lewis acid, and solvent. The results are provided in the table below.
  • Diphenyl ether 4,4'-dicarbonyl dichloride was polymerized with diphenyl ether according to the procedure of Example 17, workup B, except that (1) the monomers were added directly to the reactor, instead of from a stock solution, (2) the equivalent ratio of aluminum chloride to acid halide groups was 2.0, (3) no lithium chloride was used, and (4) no capping agents were used.
  • the polymer obtained an inherent viscosity of
  • Diphenyl ether 4,4'-dicarbonyl dichloride was polymerized with 1,4-diphenoxybenzene according to the procedure of Example 17, workup B, except that (1) the monomers were added directly to the reactor, instead of from a stock solution, (2) the equivalent ratio of aluminum chloride to acid halide groups was 2.0, (3) no lithium chloride was used, and (4) no capping agents were used.
  • the polymer obtained had an inherent viscosity of
  • 4,4'-Diphenoxybenzophenone was polymerized with terephthaloyl chloride, with and without added lithium chloride, according to the procedure of Example 17, workup A, with these exceptions: (1) the reactions were not capped: (2) aluminum chloride was added to a suspension of the monomers in 1,2-dichloroethane, instead of vice-versa; (3) where lithium chloride was used, it was used in the amount of 2.0 equivalents per equivalent of carbonyl groups in the reaction mixture; and (4) aluminum chloride was used in a 10 equivalent % excess over the total equivalents of carbonyl groups and lithium chloride.
  • This example demonstrates the necessity for controlling the excess of aluminum chloride where the monomers used are terephthaloyl chloride and a comonomer as defined in I(ii)(a), I(ii)(b), or I(i)(d) and where the polymerization is conducted in the substantial absence of Lewis base.
  • Terephthaloyl chloride was polymerized with 1,4-diphenoxybenzene by the procedure of Example 17, workup A, with these exceptions: (1) no capping agents were employed, (2) the "per cent loading," as defined hereinbefore, was about 12S5 (Example 17 calculates to about 16), (3) no lithium chloride was added, and (4) the equivalent % excess of aluminum chloride was either 10 or 100, relative to the total equivalents of acid chloride groups present. The reaction with only 10 equivalent % excess aluminum chloride gave polymer with inherent viscosity 1.59. The reaction with 100 equivalent % excess aluminum chloride gave polymer with inherent viscosity 0.18.
  • This example demonstrates the benefits of polymerizing terephthaloyl chloride with a comonomer as defined in I(ii)(a), I(ii)(b), or I(ii)(c) in the presence of a Lewis base.
  • Terephthaloyl chloride was polymerized with 1 ,4-diphenoxybenzene with and without lithium chloride added, according to the procedure of Example 17, workup A, with exceptions as noted: (1) the "percent loading," as defined hereinbefore, was about 12%, (2) the polymerizations were capped by employing 0.8 mole % excess of 1,4-diphenoxybenzene and 0.16 mole % of benzoyl chloride, (3) where lithium chloride was added, it was in the amount of 1 equivalent per equivalent of acid halide groups, and (4) the equivalent % excess of aluminum chloride over the sum of acid halide and lithium chloride equivalents was 10%.
  • the reaction with lithium chloride was homogeneous and gave polymer with inherent viscosity 0.91, while one without lithium chloride was heterogeneous and gave polymer of inherent viscosity 0.60.
  • the preparation of aromatic polymers in accordance with this invention has been set forth above with reference to specific embodiments thereof. It is to be understood that the specific embodiments are illustrative in nature and the invention is not limited to such embodiments.
  • the invention in its broadest aspect is directed to an electrophilic polymerization reaction in which the reaction medium comprises free Lewis acid and a complex between a Lewis acid component and a Lewis base component and, optionally, a non-protic diluent.

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Abstract

Procédé de production d'une polycétone aromatique comprenant la polymérisation d'un ou de plusieurs monomères appropriés par une réaction de polymérisation de Friedel-Crafts en recourant à un catalyseur d'acide de Lewis. Un agent de régulation, par exemple une base de Lewis, peut être ajouté au milieu de réaction et/ou la réaction est effectuée en conditions spécifiées afin d'effectuer la régulation de la réaction. Le milieu de réaction comporte, par exemple, un trichlorure d'aluminium servant d'acide de Lewis, une base organique de Lewis, par exemple la N,N-diméthylformamide ou une base inorganique de Lewis, par exemple un chlorure de sodium ou de lithium, ainsi qu'un diluant, par exemple un chlorure de méthylène ou un dichloroéthane. On fait varier la quantité d'acide de Lewis, la quantité de base de Lewis, la température de la réaction et le monomère à un taux molaire diluant en fonction du système monomère afin d'obtenir des polymères pratiquement linéaires, pouvant subir un traitement par fusion, de poids moléculaire élevé, par exemple un poly(carbonyle-p-phénylène-oxy-p-phénylène),un poly(carbonyle-p-phénylène-oxy-p-phénylène-oxy-p-phénylène), ou autres. Le présent procédé permet également de produire de manière avantageuse des copolymères contenant jusqu'à 30% en poids d'un comonomère d'halogénure de sulfanyle aromatique.
EP84901676A 1983-03-31 1984-04-02 Preparation de polymeres aromatiques Withdrawn EP0138990A1 (fr)

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KR102250302B1 (ko) * 2018-12-12 2021-05-07 한화솔루션 주식회사 개선된 폴리에테르케톤케톤 제조방법 및 이에 의해 제조된 폴리에테르케톤케톤
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EP0124276A3 (en) 1985-12-27
EP0124276B1 (fr) 1989-03-22
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IL71422A0 (en) 1984-07-31
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CA1244996A (fr) 1988-11-15
ATE41667T1 (de) 1989-04-15
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ATE81518T1 (de) 1992-10-15

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